Designation A603 − 98 (Reapproved 2014) Standard Specification for Zinc Coated Steel Structural Wire Rope1 This standard is issued under the fixed designation A603; the number immediately following th[.]
Designation: A603 − 98 (Reapproved 2014) Standard Specification for Zinc-Coated Steel Structural Wire Rope1 This standard is issued under the fixed designation A603; the number immediately following the designation indicates the year of original adoption or, in the case of revision, the year of last revision A number in parentheses indicates the year of last reapproval A superscript epsilon (´) indicates an editorial change since the last revision or reapproval 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 Scope 1.1 This specification covers zinc-coated steel structural wire rope, prestretched or nonprestretched for use where a high-strength, relatively flexible prefabricated zinc-coated multiple-wire tension member is desired as a component part of a structure Materials and Manufacture 1.2 The wire rope is furnished with Class A weight zinccoated wires throughout It can be furnished with Class B weight or Class C weight zinc-coated outer wires or Class B weight or Class C weight zinc-coated wires throughout where additional corrosion protection is required 5.1 Base Metal—The base metal shall be carbon steel made by the open-hearth, basic-oxygen, or electric-furnace process and of such quality that the finished wire rope and the hard-drawn individual zinc-coated wires coated by the hot-dip or electrolytic process shall have the properties and characteristics as prescribed in this specification 1.3 The values stated in inch-pound units are to be regarded as standard The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard 5.2 Zinc—The slab zinc when used shall conform to Specification B6 or better Physical Properties Referenced Documents 6.1 Tensile Properties: 6.1.1 The zinc-coated wire used in the wire rope shall conform to the mechanical properties in Table prior to fabrication, but the wire test sample may be prestretched to 55 % of the minimum tensile strength specified in Table prior to conducting the tests 6.1.2 The tensile strength and the stress at 0.7 % extension shall be based on the actual cross-sectional area of the finished wire, including the zinc coating 6.1.3 Test Specimens—The test specimens shall be free of bends or kinks other than the curvature resulting from the usual coiling operation The hand straightening necessary to permit insertion of the specimen in the jaws of the testing machine shall be performed by drawing between wood blocks or by some other equally satisfactory means 2.1 ASTM Standards:2 A90/A90M Test Method for Weight [Mass] of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings A902 Terminology Relating to Metallic Coated Steel Products B6 Specification for Zinc Terminology 3.1 Definitions—For definitions of terms used in this specification, see Terminology A902 Prestretched (see 8.3) or nonprestretched, Coating-weight class if other than Class A (Table 5), Mechanical tests if required (see 10.1), Special packaging requirements (Section 13), and Inspection (Section 12) Ordering Information 4.1 Orders for material under this specification shall include the following information: 4.1.1 Length of wire rope, 4.1.2 Nominal diameter of wire rope (Tables 1-4), 6.2 Stress at 0.7 % Extension Under Load—The value of stress at 0.7 % extension under load shall be determined by one of the following procedures, depending on the type of extensometer used: 6.2.1 Non-Autographic Extensometer—When a nonautographic extensometer is used to measure the 0.7 % extension, it shall have a gage length of 10 in (254 mm), and it shall be so graduated that the smallest division corresponds to a strain not larger than 0.0001 in./in (0.0001 mm/mm) of gage length Apply a load corresponding to the tensile stress indicated in Table 5, using the nominal diameter of the This specification is under the jurisdiction of ASTM Committee A05 on Metallic-Coated Iron and Steel Productsand is the direct responsibility of Subcommittee A05.12 on Wire Specifications Current edition approved Aug 1, 2014 Published August 2014 Originally approved in 1970 Last previous edition approved in 2009 as A603 – 98 (2009)ε1 DOI: 10.1520/A0603-98R14 For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org For Annual Book of ASTM Standards volume information, refer to the standard’s Document Summary page on the ASTM website Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959 United States A603 − 98 (2014) TABLE Properties of Single-Class Zinc-Coated Steel Structural Wire Rope (Inch-Pound Units) Minimum Breaking Strength in Tons of 2000 lb Nominal Diameter, in Class A Coating Throughout Class B Coating Throughout Class C Coating Throughout ⁄ 6.5 8.8 11.5 14.5 18.0 21.5 26.0 30.0 35.0 40.0 45.7 57.8 72.2 87.8 104.0 123.0 143.0 164.0 186.0 210.0 235.0 261.0 288.0 317.0 347.0 379.0 412.0 475.0 555.0 640.0 730.0 6.2 8.4 11.0 13.8 17.2 20.5 24.8 28.6 33.4 38.2 43.6 55.1 68.9 83.8 99.2 117.0 136.0 156.0 177.0 200.0 224.0 249.0 275.0 302.0 331.0 362.0 393.0 453.0 529.0 611.0 696.0 5.9 8.0 10.5 13.2 16.4 19.5 23.6 27.3 31.8 36.4 41.5 52.5 65.6 79.8 94.5 112.0 130.0 149.0 169.0 191.0 214.0 237.0 262.0 288.0 315.0 344.0 374.0 432.0 504.0 582.0 664.0 38 ⁄ 16 ⁄ 12 ⁄ 16 ⁄ ⁄ 3⁄ 13⁄16 7⁄ 15⁄16 1 1⁄ 1⁄ 3⁄ 1⁄ 5⁄ 3⁄ 7⁄ 2 1⁄ 1⁄ 3⁄ 1⁄ 2 5⁄ 3⁄ 7⁄ 3 1⁄ 1⁄ 3⁄ 4 58 11 16 Approximate Gross Metallic Area, in.2 Approximate Weight/ft, lb 0.065 0.091 0.119 0.147 0.182 0.221 0.268 0.311 0.361 0.414 0.471 0.596 0.745 0.906 1.076 1.270 1.470 1.690 1.920 2.170 2.420 2.690 2.970 3.270 3.580 3.910 4.250 5.040 5.830 6.670 7.590 0.24 0.32 0.42 0.53 0.65 0.79 0.95 1.10 1.28 1.47 1.67 2.11 2.64 3.21 3.82 4.51 5.24 6.03 6.85 7.73 8.66 9.61 10.60 11.62 12.74 13.90 15.11 18.00 21.00 24.00 27.00 TABLE Properties of Single-Class Zinc-Coated Steel Structural Wire Rope (SI Units) Minimum Breaking Strength in Metric Tons Nominal Diameter, mm Class A Coating Throughout Class B Coating Throughout Class C Coating Throughout 9.53 11.11 12.70 14.29 15.88 17.46 19.05 20.64 22.23 23.81 25.40 28.58 31.75 34.93 38.10 41.28 44.45 47.63 50.80 53.98 57.15 60.33 63.50 66.68 69.85 73.03 76.20 82.55 88.90 95.25 101.60 5.9 8.0 10.4 13.2 16.3 19.5 23.6 27.2 31.8 36.3 41.5 52.4 65.5 79.7 94.3 112.0 130.0 149.0 169.0 190.0 213.0 237.0 261.0 288.0 315.0 344.0 374.0 431.0 504.0 581.0 662.0 5.6 7.6 10.0 12.5 15.6 18.6 22.5 25.9 30.3 34.7 39.6 50.0 62.5 76.0 90.0 106.0 124.0 142.0 161.0 182.0 203.0 226.0 249.0 274.0 300.0 328.0 356.0 411.0 480.0 554.0 632.0 5.4 7.3 9.5 12.0 14.9 17.7 21.4 24.8 28.8 33.0 37.6 47.6 59.5 72.4 85.7 101.0 118.0 135.0 153.0 173.0 194.0 215.0 238.0 261.0 286.0 312.0 340.0 392.0 458.0 528.0 602.0 Approximate Gross Metallic Area, mm2 Approximate Weight/m, kg 41.9 58.7 76.8 94.8 117.4 142.6 172.9 200.7 232.9 267.1 303.9 384.5 480.7 584.6 694.2 819.4 948.4 1090.4 1238.8 1400.1 1561.4 1735.6 1916.2 2109.8 2309.8 2522.7 2742.1 3251.8 3761.5 4303.5 4897.1 0.36 0.48 0.62 0.79 0.97 1.18 1.41 1.64 1.90 2.19 2.48 3.14 3.93 4.78 5.68 6.71 7.80 8.97 10.19 11.50 12.89 14.30 15.77 17.29 18.96 20.68 22.48 26.78 31.25 35.71 40.18 A603 − 98 (2014) TABLE Properties of Multi-Class Zinc-Coated Steel Structural Wire Rope (Inch-Pound Units) Minimum Breaking Strength in Tons of 2000 lb Nominal Diameter, in Class A Coating Throughout Class B Coating Outer Wires Class A Coating Inner Wire Class C Coating Outer Wires Class A Coating Inner Wires Approximate Gross Metallic Area, in.2 Approximate Weight/ft, lb ⁄ 6.5 8.8 11.5 14.5 18.0 21.5 26.0 30.0 35.0 40.0 45.7 57.8 72.2 87.8 104.0 123.0 143.0 164.0 186.0 210.0 235.0 261.0 288.0 317.0 347.0 379.0 412.0 475.0 555.0 640.0 730.0 6.3 8.5 11.1 14.0 17.4 20.8 25.1 29.0 33.8 38.6 44.1 55.8 69.7 84.8 100.0 120.0 140.0 160.0 182.0 205.0 230.0 255.0 281.0 310.0 339.0 372.0 405.0 466.0 545.0 628.0 717.0 6.1 8.2 10.7 13.5 16.8 20.0 24.2 28.0 32.6 37.3 42.6 53.9 67.3 81.8 96.9 117.0 136.0 156.0 177.0 200.0 224.0 249.0 275.0 302.0 331.0 365.0 397.0 457.0 534.0 616.0 703.0 0.065 0.091 0.119 0.147 0.182 0.221 0.268 0.311 0.361 0.414 0.471 0.596 0.745 0.906 1.076 1.270 1.470 1.690 1.920 2.170 2.420 2.690 2.970 3.270 3.580 3.910 4.250 5.040 5.830 6.670 7.590 0.24 0.32 0.42 0.53 0.65 0.79 0.95 1.10 1.28 1.47 1.67 2.11 2.64 3.21 3.82 4.51 5.24 6.03 6.85 7.73 8.66 9.61 10.60 11.62 12.74 13.90 15.11 18.00 21.00 24.00 27.00 38 ⁄ 16 ⁄ 12 ⁄ 16 ⁄ ⁄ 3⁄ 13⁄16 7⁄ 15⁄16 1 1⁄ 1⁄ 3⁄ 1⁄ 5⁄ 3⁄ 7⁄ 2 1⁄ 1⁄ 3⁄ 1⁄ 2 5⁄ 3⁄ 7⁄ 3 1⁄ 1⁄ 3⁄ 4 58 11 16 elongation extensometer Continue the application of load until fracture occurs Record the elongation attained from the elongation extensometer and add to it 0.7 % obtained from the stress at 0.7 % extensometer to get the total elongation specimen Maintain this load while a 10-in extensometer is attached and adjusted to the initial setting shown in Table Then increase the load uniformly until the extensometer indicates an extension of 0.07 in (1.78 mm) or 0.7 % extension Record the load for this extension The stress corresponding to this load shall meet the requirements for the stress of 0.7 % extension specified in Table 6, depending on the class of coating under consideration Hold the specimen at 0.7 % extension under load and remove the extensometer used to measure the stress at 0.7 % extension; then replace it with an elongation extensometer Continue the application of load until fracture occurs Record the elongation attained from the elongation extensometer and add to it 0.7 % obtained from the stress at 0.7 % extensometer to get the total elongation 6.2.2 Autographic Extensometer—When an autographic extensometer is used, it shall have a gage length of at least in (50.8 mm) and the magnification of strain shall not be less than 250 Apply a load, corresponding to the tensile stress indicated in Table 5, using the nominal diameter of the specimen Maintain this load and attach the extensometer Then increase the load uniformly until the extension recorded by the extensometer is at least 0.7 % Determine the load at 0.7 % extension from the load-strain curve The stress corresponding to this load shall meet the requirements for stress at 0.7 % extension prescribed in Table 6, depending on the class of coating under consideration Hold the specimen at 0.7 % extension under load and remove the extensometer used to measure the stress at 0.7 % extension; then replace it with an NOTE 1—The extensometer used for the stress at 0.7 % extension and the elongation extensometer may be the same instrument Two separate instruments are advisable in that the more sensitive stress at 0.7 % extensometer which could be damaged when the wire fractures, may be removed following the determination of the 0.7 % extension The elongation extensometer may be constructed with less sensitive parts or be constructed in such a way that little damage would result if fracture occurs while the extensometer is attached to the specimen 6.3 Elongation—In determining total elongation (elastic plus plastic extension) autographic or extensometer methods may be employed If fracture takes place outside the middle third of the gage length, the elongation value obtained may not be representative of the material 6.4 Tensile Strength—The tensile strength is determined from the maximum load during the total elongation test 6.5 Ductility of Steel—The zinc-coated wire, prior to fabrication into wire rope, shall be capable of being wrapped two turns in a close helix at a rate not exceeding 15 turns/min around a cylindrical steel mandrel equal to three times the nominal diameter of the wire under test without fracture of the wire 6.6 Weight of Zinc Coating—The weight of the zinc coating on the individual wires prior to the fabrication of the wire rope A603 − 98 (2014) TABLE Properties of Multi-Class Zinc-Coated Steel Structural Wire Rope (SI Units) Minimum Breaking Strength in Metric Tons Nominal Diameter, mm Class A Coating Throughout Class B Coating Outer Wires Class A Coating Inner Wires Class C Coating Outer Wires Class A Coating Inner Wire Approximate Gross Metallic Area, mm2 Approximate Weight/m, kg 9.53 11.11 12.70 14.29 15.88 17.46 19.05 20.64 22.23 23.81 25.40 28.58 31.75 34.93 38.10 41.28 44.45 47.63 50.80 53.98 57.15 60.33 63.50 66.68 69.85 73.03 76.20 82.55 88.90 92.25 101.60 5.9 8.0 10.4 13.2 16.3 19.5 23.6 27.2 31.8 36.3 41.5 52.4 65.5 79.7 94.3 112.0 130.0 149.0 169.0 190.0 213.0 237.0 261.0 288.0 315.0 344.0 374.0 431.0 504.0 581.0 662.0 5.7 7.7 10.1 12.7 15.8 18.9 22.8 26.3 30.7 35.0 40.0 50.6 63.2 76.9 91.2 109.0 127.0 145.0 165.0 186.0 208.0 231.0 255.0 281.0 308.0 338.0 367.0 423.0 494.0 570.0 650.0 5.5 7.4 9.7 12.2 15.2 18.1 22.0 25.4 29.6 33.8 38.6 48.9 61.1 74.2 87.9 106.0 124.0 142.0 161.0 182.0 203.0 226.0 249.0 274.0 300.0 331.0 360.0 415.0 485.0 559.0 638.0 41.9 58.7 76.8 94.8 117.4 142.6 172.9 200.7 232.9 267.1 303.9 384.5 480.7 584.6 694.2 819.4 948.4 1090.4 1238.8 1400.1 1561.4 1735.6 1916.2 2109.8 2309.8 2522.7 2742.1 3251.8 3761.5 4303.5 4897.1 0.36 0.48 0.62 0.79 0.97 1.18 1.41 1.64 1.90 2.19 2.48 3.14 3.93 4.78 5.68 6.71 7.80 8.97 10.19 11.50 12.89 14.30 15.77 17.29 18.96 20.68 22.48 26.78 31.25 35.71 40.18 TABLE Initial Settings for Determining Stress at 0.7 % Extension Nominal Diameter in 0.040 to 0.089, incl 0.090 to 0.119, incl 0.120 and largerA Initial Stress mm 1.270 to 2.283, incl 2.286 to 3.045, incl 3.048 and largerA ksi 14 28 42 Initial Setting of Extensometer, in./in or mm/mm 0.0005 (0.05 % extension) 0.0010 (0.10 % extension) 0.0015 (0.15 % extension) MPa 100 190 290 A This is not to imply that larger wire will be manufactured to any unlimited diameter It only implies that the wire sizes chosen by the strand manufacturer must meet the requirements of this specification TABLE Mechanical Requirements Zinc Coating Class A B C Stress at 0.7 % Extension Under Load, in mm psi MPa psi MPa Total Elongation in 10 in or 250 mm, min, % 0.040 to 0.110 0.111 and largerA 0.090 and largerA 0.090 and largerA 1.016 to 2.794 2.820 and largerA 2.286 and largerA 2.286 and largerA 150 000 160 000 150 000 140 000 1030 1100 1030 970 220 000 220 000 210 000 200 000 1520 1520 1450 1380 2.0 4.0 4.0 4.0 Nominal Diameter Tensile Strength, A This is not to imply that larger wire will be manufactured to any unlimited diameter It only implies that the wire sizes chosen by the strand manufacturer must meet the requirements of this specification shall be not less than that specified in Table when tested in accordance with the stripping test of Test Method A90/A90M removed by rubbing with the bare fingers Loosening or detachment during the adherence test of superficial small particles of zinc, formed by mechanical polishing of the surface of zinc-coated wire, shall not be considered cause for rejection 6.7 Adherence of Coating—The zinc-coated wire, prior to fabrication into wire rope, shall be capable of being wrapped two turns in a close helix at a rate not exceeding 15 turns/min around a cylindrical steel mandrel equal to five times the nominal diameter of the wire under test without cracking or flaking the zinc coating to such an extent that any zinc can be 6.8 Finish—The zinc-coated wire surface shall be free of imperfections not consistent with good commercial practice The coating shall be continuous and reasonably uniform A603 − 98 (2014) TABLE Minimum Weight of Coating Nominal Diameter of Coated Wire Weight of Zinc Coating, oz/ft 2of Uncoated Wire Surface 0.040 0.062 0.080 0.093 0.104 0.120 0.143 0.188 in mm Class A Coating to 0.061, incl to 0.079, incl to 0.092, incl to 0.103, incl to 0.119, incl to 0.142, incl to 0.187, incl and largerA 1.016 to 1.549, incl 1.575 to 2.007, incl 2.032 to 2.337, incl 2.362 to 2.616, incl 2.642 to 3.023, incl 3.048 to 3.607, incl 3.632 to 4.750, incl 4.775 and largerA 0.40 0.50 0.60 0.70 0.80 0.85 0.90 1.00 g/m of Uncoated Wire Surface Class B Coating Class C Coating Class A Coating Class B Coating Class C Coating 0.80 1.00 1.20 1.40 1.60 1.70 1.80 2.00 1.20 1.50 1.80 2.10 2.40 2.55 2.70 3.00 122 153 183 214 244 259 275 305 244 305 366 427 488 519 549 610 366 458 549 641 732 778 824 915 A This is not to imply that larger wire will be manufactured to any unlimited diameter It only implies that the wire sizes chosen by the strand manufacturer must meet the requirements of this specification to 95 % of the minimum breaking strength requirement, the wire rope represented shall be rejected If a specimen attains a strength equal to at least 95 % but less than 100 % of the minimum breaking strength requirement, two additional test specimens shall be cut from the same manufactured length and tested If the average test results of the original specimen and the two retest specimens fail to meet the minimum breaking strength requirement, the wire rope shall be rejected Any test, however, that fails due to faulty attachment of the sockets shall be disregarded NOTE 2—It is recognized that the surface of heavy zinc coatings, particularly those produced by the hot-dip galvanizing process, are not perfectly smooth and not devoid of irregularities Test for Coating Weight 7.1 The weight of the zinc coating shall be determined by a stripping test made on the individual wires prior to fabrication of strand, in accordance with Test Method A90/A90M Wire Rope 8.1 The zinc-coated wire rope shall consist of a plurality of strands helically preformed and laid around a core composed of a strand or another wire rope The number and size of wires and the number of layers of wires in the strands shall be determined by the manufacturer 11 Rejection and Retest of Wire 11.1 If any wire test specimens breaking within the grips or the jaws of the testing machine results in values below the specified limits for tensile strength, stress at 0.7 % extension or elongation, the results shall be considered invalid and retesting shall be required 8.2 The wire rope properties are shown in Tables 1-4 8.3 When specified, the wire rope shall be prestretched The prestretched rope shall meet the minimum modulus of elasticity as shown in Table 11.2 In case there is reasonable doubt in the first trial as the ability of the wire to meet the requirements of Sections and 7, two additional tests shall be made on samples of wire from the same coil or reel If failure occurs in either of these tests, the wire shall be rejected Joints and Splices 9.1 No splicing or joining of strands shall be permitted in the manufactured length of rope 12 Inspection 9.2 Welds made prior to wire drawing are permitted Joining of wires by welding during the stranding operation is permissible, and such joints shall be dispersed sufficiently so as to maintain the minimum breaking strength as listed in Tables 1-4 Joints made during stranding in any wire shall be recoated in a workmanlike manner with zinc or a lead-zinc compound containing a minimum of 50 % zinc 12.1 All tests and inspection shall be made at the place of manufacture unless otherwise specified and shall be so conducted as not to interfere unnecessarily with the operation of the works The manufacturer shall afford the inspector representing the purchaser all reasonable facilities to satisfy the inspector that the material is being furnished in accordance with this specification When specified, inspection may be waived, and certified copies of test reports furnished 10 Sampling and Testing of Rope 13 Packaging 10.1 If specified, a test specimen shall be taken from each manufactured length of wire rope and tested to minimum breaking strength If a specimen fails to attain a strength equal 13.1 Structural wire rope shall be packaged in coils or on reels at the discretion of the manufacturer unless otherwise TABLE Minimum Modulus of Elasticity of Prestretched Structural Wire Rope Minimum Modulus—Class A CoatingA Nominal Diameter Wire Rope in mm psi GPa ⁄ to 9.52 to 101.60 20 000 000 140 38 A For Class B or Class C weight of zinc-coated outer wires, reduce minimum modulus 000 000 psi or GPa For Class B or Class C weight of zinc-coated wires throughout, consult manufacturer A603 − 98 (2014) specified Wire rope shall be packaged in such a manner so that no permanent deformation of wires in the strand or strands in the wire rope will occur 14 Keywords 14.1 steel wire; wire; wire rope; zinc-coated wire ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned in this standard Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk of infringement of such rights, are entirely their own responsibility This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and if not revised, either reapproved or withdrawn Your comments are invited either for revision of this standard or for additional standards and should be addressed to ASTM 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